Microelectronic workpiece processing tool including a processing reactor having a paddle assembly for agitation of a processing fluid proximate to the workpiece

ABSTRACT

An integrated tool is provided including at least one workpiece processing station having a paddle assembly. In accordance with one aspect of the invention, the workpiece processing station is adapted for adjusting the level of the processing fluid relative to a workpiece, wherein the portion of the workpiece to be processed and possibly the paddle is selectively immersed within the processing fluid. In accordance with a further aspect of the invention, a paddle is provided for use proximate to a workpiece in a workpiece processing station. The paddle includes a one or more sets of delivery ports and one or more sets of fluid recovery ports. In at least one embodiment, the paddle provides for agitation of a processing fluid proximate to the surface of the workpiece. In at least another embodiment, the paddle provides for the delivery and/or recovery of one or more fluids to the portion of the workpiece to be processed. One aspect of the present invention enables the fluids supplied to the workpiece by the paddle to be limited to the space located between the workpiece and the paddle, thus avoiding mixing of these fluids with the processing fluid located within the bowl assembly not supplied by the paddle.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

The present invention generally relates to an apparatus for processing amicroelectronic workpiece. More particularly, the present invention isdirected to a microelectronic workpiece processing tool having a reactorthat includes a paddle assembly, which moves relative to the workpiecefor facilitating the processing of a microelectronic workpiece. Forpurposes of the present application, a microelectronic workpiece isdefined to include a substrate upon which microelectronic circuits orcomponents, data storage elements or layers, and/or micro-mechanicalelements are formed.

During the processing of a workpiece, the portion of the workpiece to beprocessed is often exposed to a processing fluid designed to bring abouta desired alteration of the surface of the workpiece. In many instances,the alteration of the surface of the workpiece involves a particularchemical reaction that takes place at the surface. As the reaction takesplace at the surface, the reactants from the processing fluid areconsumed and/or chemical byproducts are released into the fluid. Inorder to maintain the desired forward reaction at the workpiece surfaceat optimal levels, it is often necessary to continuously replenish theprocessing fluid proximate the workpiece surface that is processed.

One known technique for replenishing the processing fluid proximate theworkpiece surface includes spinning the workpiece to agitate theprocessing fluid near the surface of the workpiece. In this way,relatively fresh processing fluid whose chemical concentrations have notyet been significantly affected by the localized reactions taking placeat the surface of the workpiece will continuously replace the spentprocessing fluid.

There are instances, however, in which spinning a workpiece relative tothe processing fluid is undesirable. For example, rotation of theworkpiece may be undesirable when electroplating certain materials ontoa workpiece where the deposited material must be uniformly aligned in aparticular magnetically polarized direction. Such processes are used inthe formation of certain read/write heads. In such processes, anexternal magnetic field is applied to the processing area, whichmagnetically aligns the material to be plated prior to the materialbeing deposited. If the workpiece within the magnetic field were to bespun, the orientation of the magnetic field with respect to theworkpiece would be continuously changing. A continuously changingorientation of the magnetic field would disrupt the formation of thedesired magnetically uniform deposition.

In view of the foregoing, other methods for agitating the processingfluid have been developed for insuring the continuous replenishment ofthe processing fluid proximate the workpiece surface under process.Namely, a paddle is used that physically moves through the processingfluid relative to and proximate to the workpiece surface to therebyagitate the processing fluid near the surface. Such agitation has theeffect of replenishing the processing fluid proximate the workpiecesurface.

In addition to agitating the processing fluid, the paddle motion hasbeen separately developed to limit processing to a portion of the areaof the workpiece surface that is to be processed. In essence, thisprovides localized control of the processing of the workpiece, includinglocalized control of the application of processing fluids. To this end,the paddle is directed to move across the workpiece in a predefinedmanner, selectively applying chemistry and/or processing power at anyone time to only a portion of the total area to be processed. Techniqueswhich provide both linear and spiral movement of the paddle relative tothe workpiece have been previously developed.

In these instances, concurrent processing of the entire portion of theworkpiece to be processed can produce undesirable or incomplete results.In at least one instance a paddle has been used to produce a controlledlinear flow of the processing across the area to be processed. Thepaddle is used to selectively supply processing fluid to only a portionof the surface at any one time. The direction of the processing issimilarly controlled. The direction of the processing is controlled inprocesses where the specific order in which the separate portions of thesurface are processed is important.

One example of where the application of processing fluid for processinga workpiece in a controlled fashion has been used is in theelectroetching or removal of a material from the surface of theworkpiece. In such instances, the material being removed provides theconductive path for supplying a necessary portion of the processingpower. As a result, the removal of material must be performed in agenerally controlled manner, since global removal of the entireconductive surface of the workpiece to be processed would result in theetching away of portions of the conductive layer located proximate tothe source of processing power prior to those areas located remote fromthe processing power source. This would result in electrical isolationof such remote areas from the processing power prior to the completionof the electroetch in those areas. By selectively applying the etchingprocess and beginning with the areas furthest from the processing powersource, the likelihood of electrically isolating a region prior tocompleting the electroetching in that region is reduced.

In addition to supplying processing fluid to the surface of theworkpiece, previous paddles have been similarly equipped with aconductive surface coupled to a power source. Accordingly, processingpower can be supplied to the paddle for the purpose of acting as anelectrode in an electrochemical process.

However, in known systems, the processing fluid supplied by the paddlehas been allowed to run off of the workpiece and the paddle into theprocessing chamber. Effectively the processing fluid associated with theelectroetch process is then unavoidably present throughout theprocessing chamber. The presence of processing fluid throughout theprocessing chamber may preclude the use of the same processing chamberfor use in a subsequent processing step, especially where a differentprocessing fluid is used. The processing fluid present from thepreceding step may provide a source of chemical contamination or mayresult in the mixing of chemicals, which may produce undesirableresults. Accordingly, under these circumstances, it may be verydifficult to use the same processing chamber for other processing steps.As such, further processing reactors must be incorporated into theprocessing tool in order to execute the further processing steps. Thisresults in an increased cost for the tool as well as an increase in therequired tool footprint.

In view of the cross-contamination issues noted above, the developmentof paddles for providing localized processing of the surface of theworkpiece has proceeded independent of the development of paddles foragitating a processing fluid proximate to the workpiece. The risk ofcross contamination of the chemistries between each of the steps rendersthe co-development of these differing approaches counter-intuitive. As aresult, the use of a paddle assembly within a given processing chamberhas been effectively limited to a single processing step or purpose. Thepresent inventors, however, have ignored such conventional wisdom andhave developed a reactor for processing a microelectronic workpiece thatemploys a multi-purpose paddle assembly design that effectively reducesand/or eliminates many of the cross-contamination issues. In addition tothe unique paddle assembly design, the reactor further incorporatesunique features that enable it to be used to affect multiple processesat a single processing station. Still further, novel microelectronicworkpiece processes and processing sequences naturally evolve from theunique reactor and/or paddle assembly design.

BRIEF SUMMARY OF THE INVENTION

In accordance with one independent aspect of the present invention anintegrated tool for processing a workpiece is set forth including atleast one processing station. The processing station comprises a bowlassembly, and a head assembly for receiving a workpiece and orientingthe workpiece within the bowl assembly. The processing station furtherincludes a paddle assembly, which includes a paddle adapted for movementrelative to the workpiece when the workpiece is disposed on the headassembly within the bowl assembly. The processing station furthercomprises a fluid inlet for supplying processing fluid to the bowlassembly, and at least one fluid path for adjusting the position of thelevel of the processing fluid relative to the workpiece between a firstposition and a second position wherein when in a first position at leastthe portion of the workpiece to be processed is immersed within theprocessing fluid, and wherein when in the second position the portion ofthe workpiece to be processed is no longer immersed within theprocessing fluid. The position of the level of the processing fluidrelative to the workpiece between a first position and a second positionis controlled by a fluid level control mechanism. The fluid levelcontrol mechanism selectively controls the relative level of theprocessing fluid with respect to the workpiece by controlling the atleast one fluid path.

In accordance with another independent aspect of the present invention aprocessing station is set forth for processing a workpiece. Theprocessing station comprises a bowl assembly, and a head assembly forreceiving a workpiece and orienting the workpiece within the bowlassembly. The processing station further includes a paddle assembly,which includes a paddle adapted for movement relative to the workpiecewhen the workpiece is disposed on the head assembly within the bowlassembly. The processing station further comprises a fluid inlet forsupplying processing fluid to the bowl assembly, and at least one fluidpath for adjusting the position of the level of the processing fluidrelative to the workpiece between a first position and a second positionwherein when in a first position at least the portion of the workpieceto be processed is immersed within the processing fluid, and whereinwhen in the second position the portion of the workpiece to be processedand possibly the paddle is no longer immersed within the processingfluid. The position of the level of the processing fluid relative to theworkpiece to between a first position and a second position iscontrolled by a fluid level control mechanism. The fluid level controlmechanism selectively controls the relative level of the processingfluid with respect to the workpiece by controlling the at least onefluid path.

In accordance with one embodiment of the processing station, the paddlesupplies a fluid to the space between the paddle and the workpiece andrecovers the fluid. The supplied fluid is confined to the space betweenthe paddle and the workpiece prior to the fluid being recovered by thepaddle.

In accordance with yet another independent aspect of the presentinvention a paddle for use proximate to a workpiece in a workpieceprocessing station is set forth. The paddle includes a surface, whichfaces the workpiece and comprises one or more sets of fluid deliveryports, and one or more sets of fluid recovery ports.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an isometric view of an integrated processing tool inaccordance with one embodiment of the present invention in which thetool is shown with several panels removed.

FIG. 2 is a further isometric view of the integrated processing toolshown in FIG. 1.

FIG. 3 is a top plan view of the tool deck of the embodiment of theintegrated a processing tool shown in FIGS. 1 and 2.

FIG. 4 is an isometric view of one embodiment of a processing stationsuitable for use in the embodiment of the tool shown in FIGS. 1-3,wherein the processing station incorporates one embodiment of a paddleassembly constructed in accordance with one aspect of the presentinvention.

FIG. 5 is a front sectional view of the embodiment of the processingstation shown in FIG. 4.

FIG. 6 is a side sectional view of the embodiment of the processingstation shown in FIGS. 4 and 5.

FIG. 7 is a side, cross-sectional view of one embodiment of a bowlassembly that is suitable for use in the processing station shown inFIGS. 4-6.

FIG. 8 is an isometric view of the embodiment of the bowl assembly shownin FIG. 7.

FIG. 9 is a top isometric view of one embodiment of an anode assemblysuitable for use in the bowl assembly shown in FIGS. 7 and 8.

FIG. 10 is a bottom isometric view of the anode assembly shown in FIG.9.

FIG. 11 is a top isometric view of the anode assembly shown in FIGS. 9and 10, wherein the anode assembly includes a square anode.

FIG. 12 is an exploded isometric view of the embodiment of the paddleassembly used the processing station shown in FIGS. 4-6.

FIG. 13 is an exploded isometric view of one embodiment of a chassissub-assembly suitable for use in the paddle assembly shown in FIG. 12.

FIG. 14 is an exploded isometric view of one embodiment of a springfloat assembly upon which the chassis sub-assembly shown in FIG. 13rests.

FIG. 15 is a side, cross-sectional view of the spring float assemblyshown in FIG. 14.

FIG. 16 is an isometric view of one embodiment of a paddle actuationsub-assembly that may be used in the paddle assembly shown in FIG. 12,with a silhouette of a circular workpiece shown for reference purposes.

FIG. 17 is a partial isometric view of the paddle actuation sub-assemblyshown in FIG. 16.

FIG. 18 is a top plan view of one embodiment of a paddle for use in thepaddle assembly shown in FIG. 12.

FIG. 19 is a cross-sectional side view of the embodiment of the paddleshown in FIG. 18.

FIG. 20 is an enlarged cross-sectional end view of the embodiment of thepaddle shown in FIGS. 18 and 19.

FIG. 21 is an isometric view of one embodiment of a head assemblysuitable for use in the processing station shown in FIGS. 4-6.

FIG. 22 is a side, cross-sectional view of the head assembly shown inFIG. 21.

FIG. 23 is an exploded isometric view of one embodiment of a workpieceengagement mechanism for use in the head assembly shown in FIGS. 21 and22.

FIG. 24 is a cross-sectional side view of the workpiece engagementmechanism shown in FIG. 23.

FIG. 25 is an isometric top view of one embodiment of a current thiefassembly suitable for use in connection with the head assembly shown inFIGS. 21 and 22.

FIG. 26 is an isometric/cut-away view of the embodiment of the headassembly, shown in FIGS. 21 and 22, with the embodiment of the currentthief assembly, shown in FIG. 25, attached thereto.

FIG. 27 is a cross-sectional side view of a workpiece in contact withthe embodiment of the current thief assembly shown in FIG. 26, and theembodiment of the workpiece engagement mechanism, shown in FIGS. 23 and24.

FIG. 28 is an isometric view of the embodiment of the processing stationshown in, FIGS. 4-6, wherein the portion of the paddle actuationsub-assembly corresponding to FIG. 17 has been removed and placed uponthe head assembly, shown in FIGS. 21 and 22, and where the head assemblyhas been oriented in a first position for receiving a workpiece.

FIG. 29 is a partial, cross-sectional side view of the embodiment of thepaddle, shown in FIGS. 18-20, and a corresponding workpiece, in whichthe paddle is supplying a fluid to the workpiece.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 illustrate corresponding isometric views of an integratedprocessing tool 10, shown with several panels removed. The integratedprocessing tool 10 incorporates multiple processing stations 12.Workpieces are generally received within the integrated processing tool10, via cassettes containing one or more workpieces. The cassettescontaining the workpieces enter and exit the integrated processing tool10, via a door in the side of the integrated processing tool 10, wherethe cassettes are received by a pair of lift/tilt mechanisms 14. Thelift/tilt mechanisms 14 position and orient the cassettes to provideaccess to the individual workpieces contained therein. A linear conveyorsystem 16 receives the individual workpieces and relays them to thevarious processing stations 12.

Additional details in connection with the lift/tilt mechanism 14 and thelinear conveyor system 16 are provided in connection with U.S. patentapplication Ser. No. 08/990,107, pending, entitled “SemiconductorProcessing Apparatus having Linear Conveyor System”, the disclosure ofwhich is incorporated herein by reference.

In accordance with one embodiment, the linear conveyor system includestwo wafer transport units 18 or robot arms, which move independentlywith respect to one another. One of the wafer transport units 18 handlesdry workpieces, while the other wafer transport unit 18 handles wetworkpieces.

The illustrated integrated processing tool 10 further includes apre-aligner 20, which establishes the alignment of the workpiece withrespect to the integrated processing tool 10 by referencing a knownregistration notch on each of the workpieces. Prior to forwarding theworkpiece to any of the other processing stations, the wafer is placedwithin the pre-aligner 20 and the registration notch is located. Afterthe pre-aligner 20 locates the registration notch, the pre-aligner 20then makes any necessary adjustments of the orientation and alignment ofthe workpiece for facilitating proper subsequent handling. Theintegrated processing tool 10 can incorporate any one of several knownpre-aligners commonly available. An example of one such suitablepre-aligner for use in the integrated processing tool 10, as presentlyconfigured, includes a prealigner manufactured and sold by PRIAutomation, Equipe Division, under the model number PRE-201-CE.

The integrated processing tool 10 can further include variouscombinations and arrangements of individual processing stations. Onesuch configuration which is consistent with the features of the presentinvention is illustrated in FIG. 3. In connection with FIG. 3, adescription of an example of a corresponding process suitable forhandling a workpiece pursuant to the illustrated configuration issimilarly discussed. Specifically, FIG. 3 illustrates a top plan view ofthe tool deck 22 of the integrated processing tool 10, shown in FIGS. 1and 2, including multiple individual processing stations 12.

As previously noted, the integrated processing tool 10 includes a pairof lift/tilt mechanisms 14, a linear conveyor system 16 including twoindependent wafer transport units 18, and a pre-aligner 20. Theintegrated processing tool 10 further includes a pair of SRD modules 24(Spin, Rinse, Dry), a pair of pre-plate modules 26, a pair of magneticprocessing stations 28, and one non-magnetic processing station 30.

The pre-plate modules 26 generally initially prepare the surface of theworkpiece for further processing by spraying a mild acid or de-ionizedwater for wetting the surface of the workpiece and removing the oxides.The SRD modules 24 generally clean the workpiece by separately rinsingand drying the workpiece, after the workpiece has been processed. Thenon-magnetic processing station 30 is similar to the magnetic processingstation 28, with the exception that the non-magnetic station 30 does notinclude a permanent magnet positioned around the processing station forencompassing the workpiece in a magnetic field during processing. Bothtypes of processing stations 28 and 30 will be described in greaterdetail below in connection with the magnetic processing station 28.

It is important to note that the illustrated configuration representsone possible configuration, which is suitable for practicing the presentinvention, many other configurations would similarly be suitable.

As presently configured the integrated processing tool 10 is well suitedto performing a process for producing read/write heads, which includesthe following steps:

1. receiving a workpiece from a cassette and forwarding the workpiece tothe pre-aligner 20;

2. receiving the pre-aligned workpiece from the pre-aligner 20 andforwarding the workpiece to a pre-plate processing module 26, whereinthe workpiece is wet using a mild acid;

3. without drying the workpiece, forwarding the workpiece to one of themagnetic or non-magnetic processing stations 28 or 30, wherein withineach of the processing stations the workpiece is subjected to a platingstep wherein the processed surface of the workpiece is immersed within aplating fluid and wherein during the plating step the processing fluidis agitated by a paddle assembly;

4. without removing the workpiece from the magnetic or non-magneticprocessing station 28 or 30, providing an in-situ rinse wherein therelative position of the workpiece with respect to the plating fluid isaltered so as to no longer be immersed within the plating fluid, andusing the paddle assembly for simultaneously applying a rinse solutionand recovering the same;

5. repeating as often as necessary steps 3 and 4 by moving the workpiecedirectly between any one of the three magnetic or non-magneticprocessing stations 28 or 30, for building up the desired multiplelaminate layers;

6. after the last plating/in-situ rinse phase is performed, forwardingthe workpiece to the SRD module 24 dedicated to rinsing;

7. after rinsing the workpiece, forwarding the workpiece to the SRDmodule 24 dedicated to drying; and

8. after drying the workpiece, returning the workpiece to thecorresponding workpiece cassette at one of the lift/tilt mechanisms 14.

In connection with producing read/write heads the two magneticprocessing stations 28, typically include chemistry for plating anickel-iron alloy, wherein each of the stations 28 includes a solutionof nickel and iron ions of differing concentrations. The non-magneticprocessing station 30 typically includes chemistry for plating one ofpalladium-nickel, cobalt-nickel, or copper.

By plating the nickel-iron alloy in a magnetic processing station 28, ametallized layer, which is magnetically uniform, is produced. Thedetails in connection with the magnetic processing station 28 areprovided below. As previously noted producing a layer of material havinga uniform magnetic layer precludes spinning the wafer within themagnetic field. Consequently, an approach for agitating the platingfluid using a paddle agitator has been developed and is described ingreater detail below. The specific approach developed is additionallycapable of providing for a rinse step within the same processing station12, which does not adversely affect the processing fluid similarlylocated within the processing station 12, in this case a processingstation 28 or 30. Furthermore the rinse phase within the same processingstation 12 enables the workpiece to be forwarded directly to the nextappropriate processing station 12 without first performing a separaterinse phase.

The below noted paddle design is not limited to being used in connectionwith a combination plating phase/rinsing phase, but could alternativelyincorporate various other combinations of processing steps, includingcombinations, which include more than two unique steps.

FIG. 4 illustrates an isometric view of a magnetic processing station28, shown in FIG. 3, in accordance with the present invention. Aspreviously noted the non-magnetic processing station 30 is identical tothe magnetic processing station 28 with the exception that the permanentmagnet producing the magnetic field for magnetically aligning the platedmaterial in the magnetic processing station 28 would not be present.

The magnetic processing station 28 includes a bowl assembly 32, withinwhich a processing fluid is retained. Located around three sides of thebowl assembly is a “U”-shaped permanent magnet 34. The permanent magnet34 includes two sections comprised of a suitably strong rare earthmagnet 36. The two sections are located at opposite legs of the“U”-shaped magnet. In at least one embodiment, the rare earth magnetsections 36 are each comprised of a neodymium-iron-boron magnet (NdFeB).The two rare earth sections 36 are coupled together via a magnet section38 comprising a 1018 ferrous material. The magnet section 38, comprisingthe 1018 ferrous material, provides a return path for the magnetic fieldproduced between the rare earth magnetic sections 36.

Magnets made from other types of materials may also be suitable.Furthermore, while the disclosed embodiment uses a permanent magnet, anelectromagnet could also alternatively be used.

Resting within the bowl assembly 32 is a paddle assembly 40, which isdiscussed below in greater detail beginning with FIG. 12. Additionally,extending into the bowl assembly 32 is a head assembly 42, similarlydiscussed below in greater detail beginning with FIG. 21. The headassembly 42 receives a workpiece and reorients and/or repositions theworkpiece relative to the bowl assembly 32. The movement of the headassembly is facilitated by a lift and rotate assembly 44. An example ofa lift and rotate assembly is described in greater detail in connectionU.S. patent application Ser. No. 09/351,980, entitled “Lift and RotateAssembly for Use in a Workpiece Processing Station and a Method ofAttaching the Same”, now U.S. Pat. No. 6,168,695, issued Jan. 2, 2001,the disclosure of which is incorporated herein by reference. Inaccordance with one embodiment the lift and rotate assembly 44 reorientsthe head assembly 42, so as to orient the side of the workpiece to beprocessed process side down in the processing fluid. Furthermore thelevel of the workpiece is raised and lowered by the lift and rotateassembly 44 with respect to the level of the processing fluid.

FIG. 5 illustrates a front sectional view of the processing station 28,shown in FIG. 4. In addition to the features noted above in connectionwith FIG. 4, the front sectional view further illustrates an array ofdiffuser holes 46 through which the processing fluid enters the bowlassembly 32. In accordance with the disclosed embodiment the processingfluid enters the bowl assembly 32 via a pump coupled to a fluidreservoir (not shown).

Additionally shown is an anode 48 located near the base of the bowlassembly. In connection with plating a nickel-iron alloy identified inthe example process described above, and in accordance with at least oneembodiment, the anode 48 is a consumable nickel anode. Duringprocessing, nickel ions are replenished into the processing fluid fromthe consumable anode. Iron ions are replenished by adding ferrouschloride to the recirculated processing fluid.

Furthermore in accordance with one embodiment of the present inventionthe lift and rotate assembly 44 includes a variable lift controller,wherein the lift and rotate assembly 44 can further adjust the degree oflift dependent upon the actual or determined location of the top surfaceof the consumable anode 48. As more of the anode 48 dissolves into theprocessing fluid, the lift and rotate assembly 44 adjusts the relativelevel of the workpiece to maintain a nearly constant distance betweenthe anode 48 and the workpiece. Specifically, the lift and rotateassembly 44 could lower the workpiece an amount equivalent to the changein height of the consumable anode 48. In this way the field strength,which is related to the distance between the anode 48 and the workpiece,can be maintained at a relatively constant level.

In accordance with the disclosed embodiment, the anode 48 receivesprocessing power via a conductive path 50 and an electrical connection52 extending through the bottom of the bowl assembly 32 and coupling tothe bottom of the anode 48.

Furthermore additional diffuser holes 46 are located behind the anode48, through which the processing fluid enters the bowl assembly 32, andwhich can not be seen in the figures shown.

FIG. 6 illustrates a side sectional view of the magnetic processingstation 28, shown in FIGS. 4 and 5. In addition to the featurespreviously discussed in connection with FIGS. 4 and 5, FIG. 6 furtherillustrates the flow path 54 of the processing fluid entering the bowlassembly 32 via the diffuser holes 46 (FIG. 5), and the flow path 56 ofthe processing fluid exiting the bowl assembly 32. The processing fluidenters the bowl assembly 32 via a fluid inlet 57. The processing fluidexits the bowl assembly via a drainage path 58. The fluid flow paths canbe seen even more clearly in connection with FIGS. 7 and 8, whichseparately illustrates the bowl assembly 32.

FIGS. 7 and 8 illustrates the bowl assembly 32, shown in FIGS. 4-6. Asnoted above, the fluid flow paths 54 and 56 are similarly shown. Asfurther illustrated in FIG. 7 the flow path 56 exiting via the drainagepath 58, exits the bowl assembly 32 over a weir 60. The weir 60 helpsestablish the height of the processing fluid as any fluid which ishigher than the weir 60 will travel toward the weir 60 and exit thedrainage path 58. As can be seen from FIG. 6 the level of the weir 60 issuch that when the weir 60 provides the only drainage path 58 for theprocessing fluid, the fluid level will rise to a level higher than thebottom surface of the head assembly 42, when in a lowered position andany workpiece coupled thereto.

The bowl assembly 32 additionally provides for a further exit flow path62 through an opening 64 in tube 66, which can be selectively opened,and which is lower then the flow path over the weir 60. The further exitflow path 62 is coupled to a further drainage path 68 and subsequentlyto a switch valve (not shown). Once opened the further exit flow path 62will influence the level of the processing fluid in the bowl assembly 32to a level consistent with the height of tube 66 and the opening 64. Inthis way the relative level of the processing fluid with respect to thebottom of the head assembly 42 and a workpiece coupled thereto can beadjusted so that the workpiece is no longer immersed in the processingfluid, without raising the head assembly 42.

When the workpiece is maintained at a level wherein the workpiece isimmersed within the processing fluid, a processing step can occur, whichincludes the exposure of the workpiece to the processing fluid. When thefluid level of the processing fluid is adjusted relative to theworkpiece so as to no longer immerse the workpiece within the processingfluid, a processing step can occur, which is independent of theprocessing fluid located within the bowl assembly 32.

Further shown in connection with FIG. 7, is a portion of a hingeassembly 70 coupled to the anode 48, and a latch 72 coupled to the anode48 at the opposite end of the hinge assembly 70. In accordance with oneembodiment, the hinge assembly 70 comprises a pair of approximatelyC-shaped connectors 74 coupled to an anode carrier 76 (more clearlyshown in connection with FIGS. 9-11). The pair of approximately C-shapedconnectors 74 separately engage a pair of rods 78 extending fromopposite sides 80 of the bowl assembly 32.

The hinge assembly 70 helps to restrict the angle of movement of theanode 48 during installation and removal. This can be beneficial in viewof the strong magnetic forces a nickel anode or an anode formed fromanother magnetically conductive material will be subject to from themagnet 34 located around the bowl assembly 32. During installation andthe removal of the anode 48, a handle mechanism is temporarily attachedto the anode 48 for facilitating greater control of the anode 48 whilemoving the anode 48 within the magnetic field.

FIGS. 9-11 illustrate an anode assembly 80 for use in connection withthe bowl assembly 32, shown in FIGS. 7 and 8. The anode assembly 80includes an anode carrier 76, which is sized and shaped to receiveeither a square anode or a circular anode. In accordance with oneembodiment, the magnetic processing station 28 and non-magneticprocessing station 30 are configured to receive either an approximately4.5 inch square workpiece or an approximately 6 inch round workpiece.The square anode would be used in connection with a square workpiece,and a circular anode would be used in connection with a circularworkpiece.

The anode 48 is coupled to the anode carrier 76 via one or morefasteners 82 connected through the bottom of the anode carrier 76. Theanode carrier 76 further includes an opening 84 through which anelectrical connection 52 can be made to the bottom of the anode 48 forsupplying processing power thereto. The anode carrier 76 still furtherincludes a latch platform 86 upon which a latch can be hooked.

FIG. 12 illustrates an exploded isometric view of a paddle assembly 40for use in connection with the magnetic or non-magnetic processingstation 28 or 30, shown in FIGS. 4-6. The paddle assembly includes achassis sub-assembly 88, a paddle actuation sub-assembly 90 which restswithin the chassis sub-assembly 88, and a shroud 92 for enclosing thepaddle actuation sub-assembly 90. A more detailed discussion concerningeach of the noted sub-assemblies are provided below in connection withFIGS. 13-20.

FIG. 13 illustrates an exploded isometric view of the chassissub-assembly 88 for the paddle assembly 40, shown in FIG. 12. Asillustrated in FIG. 13, the exploded view of the chassis sub-assembly 88illustrates pulley rods 94 and various mounting hardware 95 forattaching the pulley rods 94 to the chassis sub-assembly 88. The pulleyrods 94 provide a point of connection for attaching correspondingpulleys 96 (FIGS. 12 and 16), which will be discussed in greater detailin connection with FIG. 16. Additionally coupled to the chassissub-assembly 88 is mounting hardware 98 for attaching a position sensor100, shown in FIG. 12.

The chassis sub-assembly 88 further provides four mounting pins 102,located at each corner of the chassis sub-assembly 88. Each of themounting pins 102 rest upon a corresponding spring float assembly 104,shown in FIGS. 14 and 15, which is positioned between the chassissub-assembly 88 of the paddle assembly 40 and the bowl assembly 32. Thespring float assemblies 104 provide a degree of float or self-adjustmentfor positioning the paddle assembly 40 with respect to the bowl assembly32.

The spring float assembly 104 is shown in FIGS. 14 and 15. FIG. 14illustrates the spring float assembly 104 in an exploded isometric view.FIG. 15 illustrates a cross sectional view of the spring float assembly104.

The spring float assembly 104 provides for a housing 106 having acentral passageway 107, within which a spring float shaft 108 isreceived. At one end of the spring float shaft 108, the shaft includes aportion 110, which is wider thereby restricting motion of the shaft 108past a specific point 112, illustrated in FIG. 15, within the shafthaving a narrower diameter. The shaft 108 is biased toward this point112 by a spring 114 similarly located within the central passageway 107of the housing 106. The end of the spring 114 opposite the point ofcontact with the shaft 108 is fixed with respect to the housing 106 by aretainer 116.

The retainer 116 is held in place by a snap ring 118. The snap ring 118is a discontinuous circular ring, which may be squeezed so as to deformthe ring so as have a smaller deformed diameter. When deformed, the snapring 118 can slide into the bottom opening 120 of the housing 106 pastthe more restrictive shaft diameter, and expand and fit within a groove122 located in the wall of the central passageway 107 having a largerdiameter, which is proximate to the opening 120.

While the spring float assembly 104 can be a separate assembly, asillustrated in connection with FIGS. 14 and 15, the spring floatassembly 104 can also be integrated as part of the paddle assembly 40 orthe bowl assembly 32.

A paddle actuation sub-assembly 90 and/or portions thereof areillustrated in connection with FIGS. 16 and 17. As shown in connectionwith FIG. 16, the paddle actuation sub-assembly 90 includes pulleys 96,which ride upon corresponding pulley rods 94, also shown in connectionwith FIG. 13. The pulleys 96 and corresponding pulley rods 94 arelocated at three of the four comers of the paddle actuation sub-assembly90. At the fourth comer of the paddle actuation sub-assembly 90 is amotor 124.

The adjacent pulleys 96, and one of the pulleys adjacent to the motor124 and the motor 124 are attached to one another via correspondingdrive belts 126. In accordance with one embodiment, the gear ratios ofthe pulleys are one to one, such that the rates of movement of the drivebelts 126 are substantially equivalent. The pulleys 96 and the drivebelts 126 enable the force supplied by the motor 124 at one side of thepaddle actuation sub-assembly 90 to be similarly supplied to theopposite side of the paddle actuation sub-assembly 90.

Attached to the drive belts 126 on each of the opposite sides is anengagement mechanism 128. The engagement mechanisms 128 each attach to acorresponding area of engagement 130 associated with a paddle 132 fortransferring the relative movement of the drive belts 126 to the paddle132. While only a single engagement mechanism 128, associated with asingle area of engagement 130 is necessary for moving the paddle 132, inthe disclosed embodiment a pair of engagement mechanisms 128 are used.Driving the paddle 132 from both ends of the paddle 132 enables a moreuniform or even movement to be achieved. The drive belt 126 associatedwith the adjoining side is coupled to a moveable portion of the positionsensor 100 (FIG. 12).

The areas of engagement 130 are coupled to the paddle 132 viacorresponding connecting assemblies 134. As a result, as the drive belts126 move, so does the paddle 132. The speed at which the paddle 132moves is related to the drive speed of the motor 124. Consequently, thespeed of the paddle 132, with respect to the workpiece, can becontrolled by controlling the speed of the motor 124.

The connecting assemblies 134 include an opening through which a pair ofcorresponding travel guides 136 are received, and upon which theconnecting assemblies 134 travel. The travel guides 136 guide themovement of the paddle 132 laterally through a relatively uniformmotion. The travel guides 136 additionally help maintain a consistentrelative spacing between the surface of a paddle and a nearby workpiece.A silhouette 138 of a workpiece is shown for reference purposes.

The travel guide 136 additionally helps to maintain relative spacingbetween the paddle 132 and the workpiece 138 via positioning points 140,located on a travel guide cross member 142. The positioning points 140mate with corresponding sockets 144 located on the head assembly 42. Thesockets 144 will be discussed in greater detail below in connection withFIGS. 21 and 28.

The positioning points 140 of the travel guide 136 are set with respectto the sockets 144 of the head assembly 42, so as to provide a relativedistance between the paddle 132 and a corresponding workpiece 138. Inaccordance with one embodiment, the relative distance is betweenapproximately 40 thousandths of an inch and 80 thousandths of an inch.

An additional set of ball assemblies 141, coupled to the travel guidecross member 142 and oriented in the opposite direction of positioningpoints 140, are provided for coupling the paddle actuation sub-assembly90 to corresponding sockets 143 (FIG. 13), which are integrated as partof the chassis sub-assembly 88.

FIGS. 18-20 illustrate various plan views of a paddle 132 for use inconnection with the paddle assembly 40, shown in FIG. 12. FIG. 20 isshown enlarged with respect to the other two views to enable easierviewing of the corresponding details associated therewith. In accordancewith one embodiment, the paddle 132 is an elongated member having anapproximately rectangular surface 146, which faces the workpiece 138, asillustrated in FIG. 19. In accordance with the same or similarembodiment, the paddle 132 has a generally triangular cross-section 148,as illustrated in FIG. 20. The triangular cross-section helps tofacilitate the desired degree of fluid agitation, when used inconnection with the processing of the workpiece 138, when the workpiece138 is immersed in the processing fluid. However some degree of fluidagitation will be achieved regardless of the cross-sectional shape ofthe paddle. Accordingly the use of other cross-sectional shapes for thepaddle 132 are possible.

The approximately rectangular surface 146 of the paddle 132 includes oneor more sets of fluid delivery ports 150 and one or more sets of fluidrecovery ports 152. In accordance with one embodiment, the paddle 132includes a single set of fluid delivery ports 150, which are generallyaligned in a row down the center of the surface 146 of the paddle 132.The fluid delivery ports 150 are coupled to a common supply channel 154,which runs the approximate length of the paddle 132. The common supplychannel 154 facilitates fluid delivery to the surface of the paddlethrough the corresponding set of fluid delivery ports 150.

In at least one embodiment, the common supply channel 154 is locatedbelow the fluid delivery ports 150. The fluid delivery ports 150 arecoupled to the common supply channel 154 by drilling down from thesurface 146 of the paddle 132 to the common supply channel 154. Thecommon supply channel 154 is open at one end 156 for receiving the fluidto be delivered, via a fluid source couple thereto.

The size of each of the fluid delivery ports 150 can be varied so as toinsure the desired amount of fluid is delivered at each point along thelength of the paddle 132. In accordance with at least one embodiment,the size of the fluid delivery ports 150 generally increase as thedistance between the fluid delivery port 150 and the open end 156 of thecommon supply channel 154 increases. One exception being proximate theclosed end of the common supply channel 154, where instead of the sizeof the fluid delivery ports 150 further increasing, the size of thefluid delivery ports begin to decrease.

The fluid source is coupled to the common supply channel 154 via aregulator, which controls the rate of fluid flow, and a switch valve,which enables or disables the fluid flow. In addition to providing themechanism for supplying a fluid to the surface 146 of the paddle 132,the set of fluid delivery ports 150 could additionally provide a sourcefor additional fluid agitation.

The surface 146 of the paddle 132 includes two sets of fluid recoveryports 152, one set located on each side of the single set of fluiddelivery ports 150. The fluid recovery ports 152 are coupled to acorresponding common return channel 158, which similarly runs theapproximate length of the paddle 132. Each set of fluid recovery ports152 facilitates providing a negative pressure with respect to thesurface 146 of the paddle 132. Because a set of fluid recovery ports 152is provided on each side of the set of fluid delivery ports 150, thefluid can readily be recovered regardless of the present direction oftravel of the paddle 132.

In addition to being offset widthwise with respect to the fluid deliveryports 150, each set of fluid recovery ports 152 are offset lengthwisewith respect to one another. By offsetting lengthwise each set of thefluid recovery ports 152, with respect to one another, both sets can becoupled to the same corresponding common return channel 158, whileminimizing their effects with respect to one another.

In at least one embodiment, the common return channel 158 is locatedbelow the common supply channel 154. The fluid recovery ports 152 arecoupled to the common return channel 154 by drilling down from thesurface 146 of the paddle 132 at an angle to the common return channel158.

The common return channel 158 similarly has an open end 160 at one endof the paddle 132. The negative pressure is created by a vacuum, whichis supplied to the set of fluid recovery ports 152 via a pump coupled tothe open end 160 of the common return channel 158. The pump is coupledto the common return channel 158 via a separator in series with a valve.The separator separates the fluids and gases received via the fluidrecovery ports 152. The rate of negative pressure at the surface 146 ofthe paddle 132 is controlled by controlling the speed of the pump.

As noted previously above, the speed of the paddle 132, with respect tothe workpiece, can be controlled by controlling the speed of the motor124. This enables the rate of movement of the paddle 132 to be altered.By altering the rate of movement of the paddle 132 the rate of agitationof the processing fluid, or the rate and/or time of exposure of acorresponding portion of the workpiece to processing conditions, whenthe paddle 132 is used to deliver and/or recover fluids with respect tothe workpiece may similarly be altered.

Furthermore the velocity of the paddle can be altered as a function oftime. The specific velocity can additionally be varied based on one ormore of a variety of processing parameters. One such example includesaltering the velocity of the paddle based on amp-minutes of processingpower supplied. Such an alteration could account or compensate forpredicted changes in chemical concentrations within the processingfluid. Other such processing parameters could additionally be used as abasis of altering the velocity of the paddle 132.

In accordance with one embodiment, the paddle 132 is formed from anon-magnetic high strength engineering plastic. In addition to plastic,the paddle 132 could alternatively be formed from titanium. Titaniumreadily forms a layer of titanium oxide, which resists plating andprovides good electrical isolation.

In at least one embodiment, one or more conductor segments could beprovided at the surface 146 of the paddle 132 for supplying processingpower thereto, so as to act as a cathode or an anode dependent upon thepolarity of the power supplied with respect to the correspondingelectrode.

Additionally the paddle 132 could incorporate additional sets of fluiddelivery ports 150 and fluid recovery ports 152, and additionalcorresponding common supply channels 154 and common return channels 158.In this way sets of fluid delivery ports 150 and fluid recovery ports152 having varying supply and recovery rates can be provided.Alternatively the additional fluid delivery ports 150 and fluid recoveryports 152 could be used to supply and recover different types ofchemicals, either simultaneously or alternatively Alternative sizes andshapes for the paddle 132 could also be used.

FIGS. 21 and 22 illustrate the head assembly 42 for receiving aworkpiece. As noted previously the head assembly reorients and/orrepositions the workpiece relative to the bowl assembly 32. The movementof the head assembly 42 is facilitated by a lift and rotate assembly 44.The head assembly 42 is coupled to the lift and rotate assembly 44 viaan arm 161. In addition to coupling the head assembly 42 to the lift,and rotate assembly 44, the arm 161 generally defines an axis ofrotation 163 (FIG. 22) about which the head assembly 42 rotates.

The head assembly 42 includes a slot 162 through which a workpiece canbe received. After the head assembly 42 receives the workpiece, theworkpiece is then lowered onto the workpiece standoffs 164. Angledsurfaces associated with the sidewalls 166 serve to properly positionthe workpiece as it is lowered onto the workpiece standoffs 164. Oneportion of the sidewalls 166 is primarily suited for properlypositioning a square workpiece as it is placed on the workpiecestandoffs 164. The other portion of the sidewalls 166 is primarilysuited for properly positioning a circular workpiece as it is placed onthe workpiece standoffs 164.

The head assembly shown in FIG. 21 further illustrates sockets 144 forreceiving positioning points 140 of the travel guide 136. The sockets144 in combination with the positioning points 140 when properlyadjusted insures a consistent spatial relationship between a workpieceand the paddle 132. A method of adjustment is illustrated in connectionwith FIG. 28, and discussed below in greater detail.

The head assembly 42 further provides for a workpiece engagementmechanism 168, which applies backside pressure against a receivedworkpiece for pressing the workpiece up and against a current thiefassembly 170 (FIGS. 25 and 26), attached thereto. The current thiefassembly 170 is coupled to the head assembly 42 via a quick releasemechanism 172. The operation of the quick release mechanism is discussedin greater detail in connection with U.S. patent application Ser. No.09/429,446, pending, entitled “Method, Chemistry, and Apparatus forNoble Metal Electroplating on a Microelectronic Workpiece”, thedisclosure of which is incorporated herein by reference.

FIGS. 22-24 illustrate in greater detail the workpiece engagementmechanism 168. Specifically, FIG. 23 provides an exploded isometric viewof the workpiece engagement mechanism 168, while FIGS. 22 and 24 providecross sectional side plan views of the workpiece engagement mechanism168, both separately (FIG. 24) and incorporated as part of the headassembly 42 (FIG. 22).

The workpiece engagement mechanism 168 includes a conductive ring base174, which has a center opening 176 through which a non-conductive basemember 178 is received. The non-conductive base member 178 has an outerdiameter, which generally corresponds to the inner diameter of theconductive ring base 174. The conductive ring base 174 includes agenerally circular depression along the interior surface, within whichthe conductive ring base 174 is adapted for receiving a first end of abiasing spring 180. Coupled to the other end of the biasing spring 180is an upper ring conductor 182. The upper ring conductor 182 is coupledto a connector 184 for receiving processing power. The biasing springbeing conductive provides a path through which the processing power isrelayed to the conductive ring base 174.

Similarly coupled between the conductive ring base 174 and the upperring conductor 182, and encompassing the biasing spring 180 is a bellows185, which has sides which expand and contract with the relative motionof the conductive ring base 174 and the upper ring conductor 182. Thebellows 185 provides a physical barrier, which prevents external fluidsfrom entering portions of the workpiece engagement mechanism 168.

Coupled to the non-conductive base member 178 is a dual acting pneumaticcylinder 186. Coupled to the dual acting pneumatic cylinder 186 are twoports 188 through which fluid lines can be connected for actuating thepneumatic cylinder 186. Actuating the pneumatic cylinder 186 creates aforce for exerting lateral pressure against the non-conductive basemember 178. The force is aligned along the same axis in both the sameand opposite direction as the corresponding force created by the biasingspring 180. The pneumatic cylinder 186 in combination with the biasingspring 180 produce a force which extends and retracts the workpieceengagement mechanism 168 so as to engage and release the workpiecereceived by the head assembly 42. The spring provides the additionalbeneficial feature that if for some reason the pneumatic cylinder 186were to lose pressure, the spring would provide sufficient force toretain the workpiece engagement mechanism 168 in a closed fail safeposition.

The pneumatic cylinder 186 similarly provides the mechanism forsupplying a backside nitrogen gas purge to the workpiece.

Additionally coupled to the pneumatic cylinder 186 is a circuit boardassembly 190 including a pair of sensors 192 for monitoring the lateraltravel of the pneumatic cylinder 186 relative to the conductive ringbase 174. In a accordance with one embodiment, the sensors 192 areoptical sensors, which detect the passage of an external flag. Theexternal flag interrupts a beam of light traveling between correspondingelements of the sensor. The flag 194 is coupled to the conductive ringbase 174, whereas the sensors are coupled to the pneumatic cylinder 186.

A first of two sensors 192 defines an open position for the workpieceengagement mechanism 168. A second of two sensors 192 defines a closedposition for, the workpiece engagement mechanism 168.

Coupled to the exterior surface of the conductive ring base 174 is abelville ring contact 196. When the workpiece engagement mechanism 168is in the closed position, contact is made with the backside surface ofa workpiece received by the head assembly 42, via the belville ringcontact 196. The belville ring contact 196 includes a continuousconductive ring around which conductive elements 198 are coupled theretoat discrete positions. The conductive elements extend inward toward thecenter of the ring. It is the discrete inwardly extending elements 198,which generally make contact with the backside of the workpiece, andsupply processing power thereto. In at least one embodiment seventy-twoconductive elements 198 are provided at seventy-two discrete positionsaround the perimeter of the belville ring contact 196.

The workpiece engagement mechanism 168 additionally includes a furtherseal 200, which is coupled to the conductive ring base 174 and partiallyencloses the belville ring contact 196.

FIG. 25 illustrates an isometric top view of a current thief assembly170 for use in connection with the head assembly 42, shown in FIGS. 21and 22. The operation of a current thief is previously well known in theart. Generally a current thief redirects the plating of material awayfrom the outer edges of the workpiece. In absence of using a currentthief, a greater amount of material is generally deposited at the outeredge of the workpiece. This is because of certain edge effects. Thecurrent thief generally moves the edge effect away from the outer edgeof the workpiece to the outer edge of the current thief The currentthief assembly 170 as shown in FIG. 25, is adapted for receiving asquare workpiece.

Accordingly, the current thief assembly 170 has a square center opening202 for receiving the square workpiece. Generally the exposed surface iscoated with a dielectric material, with the exception of the portion ofthe exposed surface immediately adjacent and extending around theworkpiece opening. The exposed portion of the conductive surface notcoated with a dielectric material functions as a current thief 204.

By altering the size and shape of the opening, and the size and shape ofthe area immediately adjacent and extending around the opening which isnot coated with a dielectric material, a current thief assembly 170 canbe adapted for use with workpieces having a variety of sizes and shapes.

It is noted that in accordance with one embodiment, the current thiefassembly 170 has an outer size and shape, which is sufficiently large toprovide a complementary surface opposite the surface of the paddle 132,which extends the full length of the paddle as the paddle moves throughits full range of travel.

The current thief assembly 170 additionally includes a pair of posts 206located on opposite sides of the current thief assembly 170. The posts206 are used for coupling the current thief assembly 170 to the headassembly 42 via the quick release mechanisms 172.

In addition to providing a physical connection, the posts 206additionally provide for an electrical connection. In the disclosedembodiment, located within the quick release mechanism 172 is a bananaplug connector 208 (FIG. 26), which is received within the post 206. Asthe post engages the quick release mechanism 172, the banana plug 208 iscompressed causing the center portion of the banana plug 208 to expandoutward and engage the internal surface of the post 206, thereby makingan electrical connection. In this way processing power can be suppliedto the current thief 204.

FIG. 26 illustrates an isometric view of the head assembly 42, shown inFIGS. 21 and 22, with the current thief assembly 170, shown in FIG. 25,attached thereto. FIG. 26 further illustrates a portion of both the headassembly 42 and the current thief assembly 170, cut away, so as toillustrate the banana plug 208 making a connection with the post 206.

FIG. 27 illustrates a cross sectional side view of the workpieceengagement mechanism 168, shown in FIGS. 23 and 24 applying backsidepressure against a received workpiece 210 for pressing the workpieceagainst the current thief assembly 170, shown in FIG. 26.

Specifically, as the conductive ring base 174 of the workpieceengagement mechanism 168 moves against the workpiece 210, the discreteinwardly extending elements 198 are pressed down and scrape into thebackside of the workpiece 210. At approximately the same time, the seal200 similarly engages the backside surface of the workpiece 210. Theworkpiece 210 is similarly brought into contact with a non-conductiveseal 212 located at the backside surface of the current thieving portion204 of the current thief assembly 170.

In connection with the above noted process, backside contact is possiblewherein the workpiece 210 has a substrate 214, which is conductive.Processing power is supplied to the portion of the workpiece 210 to beprocessed through the conductive substrate 214, and around the generallynon-conductive barrier layer 216, via a seed layer 218, which extendsaround the barrier layer 216 and contacts the substrate 214. The path ofthe processing power is illustrated by arrow 220.

While a backside contact has been disclosed in connection with thedisclosed embodiment, one skilled in the art should readily appreciatethat other embodiments incorporating front side contact would similarlybe possible.

As discussed previously in connection with one embodiment, the relativedistance between the paddle 132 and the workpiece is betweenapproximately 40 thousandths of an inch and 80 thousandths of an inch.FIG. 28 illustrates one suitable method for adjusting the paddledistance. Specifically, FIG. 28 illustrates an isometric view of theprocessing station 28 shown in, FIGS. 4-6, wherein the portion of thepaddle actuation sub-assembly 90 corresponding to FIG. 17 has beenremoved and placed upon the head assembly 42, shown in FIGS. 21 and 22,when the head assembly 42 is oriented in a position for receiving aworkpiece. More specifically positioning points 140 of the paddleactuation sub-assembly 90 are aligned with corresponding sockets 144 ofthe head assembly 42.

One of the benefits to placing the portion of the paddle actuationsub-assembly on top of the head assembly 42 is that it provides easieraccess to the gap distance, away from the rest of the paddle assembly40, which limits access thereto. This is possible because the gapdistance is controlled by positioning points 140 of the paddle actuationsub-assembly 90, the sockets 144 of the head assembly 42, and thecorresponding structure therebetween, which has been similarlypositioned onto the head assembly 42.

A blank 224 having a thickness consistent with the thickness of theworkpiece can be received within the head assembly 42, and the headassembly can be placed into a closed position. This will insure that therelative spacing of the workpiece is accounted for. The relevant portionof paddle actuation sub-assembly 90 is then placed upon the headassembly 42, wherein the positioning points 140 are aligned with thecorresponding sockets 144. A gauge for measuring spacing can then beplaced between the paddle 132 and the blank 224, and checked while thepaddle 132 is positioned at various travel points relative to the headassembly 42. If necessary the height of the paddle 132 can be adjusted.In this way the desired spacing can be provided between the paddle 132and the workpiece.

As noted previously the paddle 132, described above, is capable of beingused in connection with at least two types of processing. The first typeof processing uses the paddle 132 to facilitate fluid agitation of theprocessing fluid proximate the surface of the workpiece 138, when theportion of the workpiece 138 to be processed is immersed within aprocessing fluid. In this instance the fluid agitation is achieved bymoving the paddle relative to the portion of the workpiece 138 to beprocessed. In this way relatively fresh processing fluid whose chemicalconcentrations have not yet been been significantly affected by thelocalized effects of the reaction taking place at the surface of theworkpiece will mix in and continuously replace the stale fluid.

As also noted previously the delivery or recovery of processing fluid byone or more sets of fluid recovery ports 152 and one or more sets offluid delivery ports 150 could similarly be used to enhance fluidagitation or supply fresh chemistry proximate the workpiece 138.

The second type of processing uses the paddle to supply and recoverfluids proximate the surface of the workpiece 138, when the portion ofthe workpiece 138 to be processed is not immersed within a processingfluid. In this instance fluid is supplied to the portion of theworkpiece 138 to be processed via one or more sets of fluid deliveryports 150. In conjunction with supplying the fluid to the portion of theworkpiece 138 to be processed, the fluid may similarly be recovered viaone or more sets of fluid recovery ports 152.

By additionally recovering the fluid via one or more sets of fluidrecovery ports 152, the fluid supplied can be confined to theapproximate space located between the paddle 132 and the workpiece 138,without coming into contact with chemically distinct processing fluid,which may be similarly located in the processing station 28 or 30 orcome into contact with surfaces which may later be exposed to otherchemistry.

FIG. 29 illustrates a partial cross sectional side view of the paddle132, shown in FIGS. 18-20, and a workpiece 138, wherein the paddle 132is both supplying a fluid to the workpiece 138 and recovering a fluidsupplied to the workpiece 138.

The paddle 132 is shown moving in a direction from left to right, asillustrated by arrow 222. FIG. 29 helps to further illustrate theconfined nature of the processing fluid supplied to space between thepaddle 132 and the workpiece 138, via the set of fluid delivery ports150, wherein one or more sets of fluid recovery ports 152 are similarlyrecovering the processing fluid.

Generally the fluid is retained within the space as a result of thevolume of processing fluid not being allowed to exceed the volume offluid, which can be supported by the corresponding surface tension. Atthe same time sufficient fluid needs to be present to fill the gap.Accordingly, the rate of recovery of processing fluid via the fluidrecovery ports 152 needs to be set taking into account the rate ofsupply of processing fluid via the fluid delivery ports 150.

As a result of the movement of the paddle 132, the fluid tends to trailbehind the paddle 132. However so long as the overall fluid volume ismaintained between acceptable levels, the fluid can still be confinedwithin the appropriate space. An example of possible fluid flow withinthe volume of fluid formed within the space is illustrated by smallarrows.

In the process noted above in connection with the formation ofread/write heads, the paddle 132 is used to provide a rinse functionwhile the workpiece 138 is present within the processing station 28 or30, which similarly provides for the electroplating of material onto theworkpiece 138. After the plating step is concluded, the level of theprocessing fluid relative to the workpiece 138 is adjusted so that theworkpiece 138 is no longer immersed within the processing fluid. Thepaddle then supplies to and recovers from the workpiece 138, a fluiddifferent from the processing fluid within which the workpiece 138 waspreviously immersed. In this case the fluid is a rinse solution. Moreparticularly the rinse solution is de-ionized water. After the workpieceis rinsed, the workpiece 138 may be directly forwarded to the nextprocessing station 28 or 30.

By delivering fluids to the workpiece 138 via the space located betweenthe paddle 132 and the workpiece 138, the present system has the benefitthat a minimal volume of chemistry is used. Furthermore the area ofdelivery can be much more precisely controlled. Consequently, sprayingcan be reduced as well as backside exposure of the workpiece 138. Stillfurther, the sequential movement of the workpiece 138 through multipleprocessing stations 12 can be greatly simplified.

In the above noted example, the paddle 132 delivers de-ionized water tothe workpiece. The paddle could further supply de-ionized water, whereozone has been dissolved therein. In these or other instances a sourceof ozone may be separately supplied within the processing chamber.Furthermore, the fluid supplied by the paddle 132 could additionallyinclude a temperature differential, wherein a cooled or a heated fluidis supplied to the workpiece.

As previously noted, the specific construction of the paddle 132 couldbe adjusted to accommodate further fluid supplies and fluid recoveriesto allow even greater flexibility, including multiple sequentialprocesses simultaneously.

Other processes which would be also suitable for use with the expandedcapabilities of the paddle 132, provided for by the present invention,include: electroplating, electroless plating; etching metal; developingphoto resist; cleaning a workpiece surface including using an acid, asolvent, and/or de-ionized water; metal lift off, thinning silicon;chemically etching; and/or chemically machining.

Numerous modifications may be made to the foregoing system withoutdeparting from the basic teachings thereof Although the presentinvention has been described in substantial detail with reference to oneor more specific embodiments, those of skill in the art will recognizethat changes may be made thereto without departing from the scope andspirit of the invention as set forth in the appended claims.

What is claimed is:
 1. A processing station for processing amicroelectronic workpiece comprising: a bowl assembly; a head assemblyfor receiving a workpiece and orienting the workpiece within the bowlassembly; a paddle assembly including a paddle and a plurality ofspaced-apart fluid delivery ports, the paddle being adapted for movementrelative to the workpiece when the workpiece is disposed on the headassembly within the bowl assembly and the fluid delivery ports beingoriented toward the workpiece when the workpiece is disposed on the headassembly within the bowl assembly; a fluid inlet for supplyingprocessing fluid to the bowl assembly; at least one fluid path foradjusting the position of the level of the processing fluid relative tothe workpiece between a first position, wherein at least the portion ofthe workpiece to be processed is immersed within the processing fluid,and a second position, wherein the portion of the workpiece to beprocessed is not immersed within the processing fluid; and a fluidcontrol level mechanism for selectively controlling the at least onefluid path thereby enabling the position of the level of the processingfluid relative to the workpiece to adjust between the first position andthe second position.
 2. A processing station as set forth in claim 1wherein said at least one fluid path includes: a first fluid outletcoupled to a drainage path, the first fluid outlet having a first flowpath opening at a height above the workpiece processing position forlimiting the level of the processing fluid to the approximate height ofthe first flow path opening; and a second fluid outlet selectivelycoupled to the drainage path, the second fluid outlet having a secondflow path opening at a height below the workpiece processing positionfor selectively lowering the level of the processing fluid to theapproximate height of the second flow path opening.
 3. A processingstation as set forth in claim 1 wherein said paddle assembly furtherincludes a motor for moving the paddle relative to the workpiece,wherein when the level of the processing fluid is at the first positionthe relative movement of the paddle agitates the processing fluidproximate the workpiece.
 4. A processing station as set forth in claim 1further comprising an electrode located within the bowl assembly.
 5. Aprocessing station as set forth in claim 4 wherein said electrode is ananode.
 6. A processing station as set forth in claim 5 wherein saidanode is a consumable anode.
 7. A processing station as set forth inclaim 6 wherein said head assembly is coupled to the bowl assembly via alift and rotate assembly.
 8. A processing station as set forth in claim7 wherein said lift and rotate assembly includes a variable lift adjustmechanism for adjusting the processing position of the workpiecerelative to the anode as the anode is consumed.
 9. A processing stationas set forth in claim 4 wherein said electrode includes a pivotmechanism for hingeably coupling the electrode to the bowl assembly. 10.A processing station as set forth in claim 9 wherein said electrodeincludes a latch mechanism located opposite the pivot mechanism forsecuring the end of the electrode relative to the bowl assembly.
 11. Aprocessing station as set forth in claim 1 wherein said head assemblyincludes a contact assembly for securing the workpiece relative to thehead assembly.
 12. A processing station as set forth in claim 11 whereinsaid contact assembly is adapted for supplying processing power to thesurface of the workpiece.
 13. A processing station as set forth in claim11 wherein said head assembly further includes a back side contact forengaging the workpiece and supplying processing power when the workpieceis secured relative to the head assembly.
 14. A processing station asset forth in claim 1 further comprising a magnet for creating a magneticfield relative to the processing position of the workpiece.
 15. Aprocessing station as set forth in claim 14 wherein said magnet is apermanent magnet.
 16. A processing station as set forth in claim 15wherein said magnet is coupled to the bowl assembly and is located so asto extend substantially around the bowl assembly.
 17. A processingstation as set forth in claim 16 wherein said magnet substantiallyextends around at least three sides of the bowl assembly.
 18. Aprocessing station as set forth in claim 1 further comprising aprocessing space substantially located between the paddle and theworkpiece when the level of the processing fluid is at the secondposition.
 19. A processing station as set forth in claim 18 wherein thepaddle assembly further includes a motor for moving the paddle and theprocessing space relative to the workpiece.
 20. A processing station asset forth in claim 19 wherein the paddle assembly further includes avariable speed motor control for adjusting the speed of the motor andthe speed with which the paddle moves relative to the workpiece.
 21. Aprocessing station as set forth in claim 18 wherein the paddle includesone or more sets of fluid delivery ports for supplying one or morefluids to the processing space substantially located between the paddleand the workpiece.
 22. A processing station as set forth in claim 21wherein the paddle further includes one or more sets of fluid recoveryports for recovering fluids supplied to the processing space.
 23. Aprocessing station as set forth in claim 22 further comprising avariable rate flow controller coupled to the fluid recovery ports forvarying the rate of recovery of the fluid supplied to the processingspace.
 24. A processing station as set forth in claim 23 wherein thevariable rate flow controller is adapted to set the rate of recovery ata level which confines the fluid supplied to the processing space to theregion within the processing space prior to the fluid being recoveredvia the fluid recovery ports.
 25. A processing station as set forth inclaim 21 wherein the paddle further includes an electrode for supplyingprocessing power to the paddle.
 26. A processing station as set forth inclaim 1 wherein said head assembly includes a current thief whichextends substantially around the workpiece.
 27. A processing station asset forth in claim 26 wherein said current thief is sized so that incombination with the workpiece the current thief and the workpiecesubstantially extend at least the full length of the paddle over therange of processing motion of the paddle.
 28. A processing station asset forth in claim 1 wherein said paddle assembly further includes amotor for moving the paddle relative to the workpiece, wherein when thelevel of the processing fluid is at the second position the relativemovement of the paddle permits the processing fluid to be deliveredacross a surface of the workpiece through the fluid delivery port.
 29. Aprocessing station as set forth in claim 1 wherein said paddle assemblyfurther includes at least one fluid recovery port positioned proximatethe workpiece when the workpiece is disposed on the head assembly withinthe bowl assembly.
 30. An integrated tool for processing a workpieceincluding at least one processing station, said processing stationcomprising: a bowl assembly; a head assembly for receiving a workpieceand orienting the workpiece within the bowl assembly; a paddle assemblyincluding a paddle and a plurality of spaced-apart fluid delivery ports,the paddle being adapted for movement relative to the workpiece when theworkpiece is disposed on the head assembly within the bowl assembly andthe fluid delivery ports being oriented toward the workpiece when theworkpiece is disposed on the head assembly within the bowl assembly; afluid inlet for supplying processing fluid to the bowl assembly; atleast one fluid path for adjusting the position of the level of theprocessing fluid relative to the workpiece between a first position,wherein at least the portion of the workpiece to be processed isimmersed within the processing fluid, and a second position, wherein theportion of the workpiece to be processed is not immersed within theprocessing fluid; and a fluid control level mechanism for selectivelycontrolling the at least one fluid path thereby enabling the position ofthe level of the processing fluid relative to the workpiece to adjustbetween the first position and the second position.
 31. A processingstation for processing a microelectronic workpiece comprising: a bowlassembly; a head assembly adapted to position a workpiece within thebowl assembly; a paddle assembly including a paddle and a plurality ofspaced-apart fluid delivery ports, the paddle being adapted for movementrelative to the workpiece when the workpiece is positioned within thebowl assembly and the fluid delivery ports being adapted to deliver afluid to a surface of the workpiece; a fluid inlet in fluidcommunication with the bowl assembly; at least one fluid path; and afluid level control operatively coupled to the at least one fluid pathand adapted to adjust a level of the processing fluid between a firstlevel, wherein a surface of the workpiece is immersed within theprocessing fluid, and a second level, wherein the surface is notimmersed within the processing fluid.
 32. A processing station forprocessing a microelectronic workpiece comprising: a bowl assembly; ahead assembly adapted to position a workpiece within the bowl assembly;a paddle means for delivering a first processing fluid flow through aplurality of spaced-apart fluid delivery ports to a surface of theworkpiece when the workpiece is positioned within the bowl assembly; afluid inlet for supplying a second processing fluid flow to the bowlassembly; and a fluid level control means adapted to adjust a level ofprocessing fluid between a first level, wherein the surface of theworkpiece is immersed within the processing fluid, and a second level,wherein the surface is not immersed within the processing fluid.
 33. Aprocessing station as set forth in claim 32 wherein the paddle means isadapted to deliver the first processing fluid flow to the surface of theworkpiece when the processing fluid is at the first level.
 34. Aprocessing station as set forth in claim 32 wherein the paddle means isadapted to deliver the first processing fluid flow to the surface of theworkpiece when the processing fluid is at the second level.